I just feel like shouting something out for the more ignorant anti-Legion bias players:
It isn't that the Legion doesn't use guns (yes of course they do), but simply that I believe there is still too many machete wielders in its ranks for it to be realistic in in fighting the NCR. That is something that cannot be denied.
More to the point, the NCR armor looks like it would have little trouble stopping the machetes regardless of how close the Legionaries are able to get.
A blood-thirsty Legionnaire against some farm boy-turned-trooper isn't going to end well for the Trooper. The only thing the NCR can one-up against the Legion is equipment and men.
Both of which matter quite a bit. Training can only go so far.
As a good historic example, why is it that ranks of inaccurate muskets that could only fire perhaps one round a minute replaced bowmen (such as skilled longbowmen) who could reliably fire 6-7 arrows per minute and with often deadly accuracy and range?
The answer? It takes only a brief amount of time for someone to learn how to load a musket and then point and shoot it. Granted they may not be quite as accurate, but they can still do significant damage in numbers (with greater penetration as well). Whereas it takes
years for a longbowman to train and be able to hit a target. When that longbowman was lost, it was far harder to replace him than it was to train a new musketman.
In other words, the Legion may have soldiers who are deadly with a machete. But when it comes down to it, no amount of training is going to be of use against even a "farm boy" with an automatic weapon in his hand who's had enough training (and the NCR soldiers do get a decent amount of training in) to reliably shoot it. The only way the Legion soldier would be able to win is if he had armor which could stop the bullets (and ad-hoc football pads certainly aren't going to do that) or if he was able to surprise the NCR trooper (which is possible but only in certain situations.)
Furthermore, as you have already stated, the Legion doesn't even have as many soldiers as the NCR does. Which means they can't afford to lose as many men (making those "suicide charges" rather silly indeed). Add this to the point I made in regards to the historic example of the longbowmen, and it takes longer to train a legionary to be a successful machete wielder than it does for the NCR to give a conscript a semi-auto weapon and tell him how to point and shoot the charging Legionaries.
The fact of the matter is that really the Legion is a poorly equipped fighting force. Regardless of how well they can throw a knife, wield a 2 foot long rusty machete, or what have you. In my opinion, they have far too few gun-wielders and far too poor armor.
Case in point: When the Service Rifle got upgraded to act like a goddamed AR15 and 5.56 started behaving like the proper armor-penetrating, day-wrecking round that it actually is, the Legion fans started [censored]ing that leather and thin sheet metal riveted onto football pads didn't stop them well enough, and the bum-rushing a combat patrol with a sharp stick and a battle cry didn't work anymore. Go figure.
I sort of agree here.